Methods of processing a substrate and forming a micromagnetic device

ABSTRACT

A method of processing a substrate with a conductive film formed thereover and method of forming a micromagnetic device. In one embodiment, the method of processing the substrate includes reducing a temperature of the substrate to a stress-compensating temperature, and maintaining the temperature of the substrate at the stress-compensating temperature for a period of time. The method also includes increasing the temperature of the substrate above the stress-compensating temperature.

This application is a continuation of application Ser. No. 11/852,716now U.S. Pat. No. 7,943,510, entitled “Methods of Processing a Substrateand Forming a Micromagnetic Device”, filed on Sep. 10, 2007, which isincorporated herein by reference.

TECHNICAL FIELD

The invention is directed, in general, to magnetic devices and, morespecifically, to a micromagnetic device, method of forming and powerconverter employing the same, and an electroplating tool and electrolyteemployable for constructing a magnetic core layer of the micromagneticdevice, and a method of processing a substrate and micromagnetic device.

BACKGROUND

A switch mode power converter (also referred to as a “power converter”)is a power supply or power processing circuit that converts an inputvoltage waveform into a specified output voltage waveform, which istypically a well-regulated voltage in electronic device applications.Power converters are frequently employed to power loads having tightvoltage regulation characteristics such as a microprocessor with, forinstance, a bias voltage of one volt or less provided by the powerconverter. To provide the voltage conversion and regulation functions,power converters include a reactive circuit element such as an inductorthat is periodically switched to the input voltage waveform at aswitching frequency that may be on the order of ten megahertz or more byan active switch such as a metal-oxide semiconductor field-effecttransistor (“MOSFET”) that is coupled to the input voltage waveform.

A power converter configured to power an integrated circuit such as amicroprocessor formed with submicron size features is generally referredto as a “point-of-load device,” and the integrated circuit is typicallylocated close to the point-of-load power converter to limit voltage dropand losses in the conductors that couple the devices together. In suchapplications, a point-of-load power converter may be required to providesubstantial current such as ten amperes or more to the integratedcircuit. As current levels for integrated circuit loads continue toincrease and the bias voltages decrease with on-going reductions inintegrated-circuit feature sizes, the size of the power converter andits power conversion efficiency become important design considerationsfor product acceptance in challenging applications for emerging markets.

A recent development direction for reducing the size of point-of-loadpower converters has been to integrate the magnetic circuit elementstherein, such as an isolation transformer or an output filter inductor,onto the same silicon substrate that is used to form the integratedcontrol and switching functions of the power converter. These designdirections have led to the development of micromagnetic devices withconductive and magnetic structures such as conductive windings andmagnetic cores with micron-scaled dimensions to complement the similarlysized elements in logic and control circuits and in the power switches.The integrated magnetic circuit elements are therein produced withmanufacturing processes and materials that are fully compatible with theprocesses and materials used to produce the correspondingsemiconductor-based circuit components. The result of the deviceintegration efforts has been to produce single-chip power convertersincluding planar inductors and transformers capable of operation at thehigh switching frequencies that are necessary for point-of-load powerconverters to provide the necessary small physical dimensions.

As an example of a process to form a magnetic device that can beintegrated onto a semiconductor substrate, Feygenson, et al.(“Feygenson”), in U.S. Pat. No. 6,440,750, entitled “Method of MakingIntegrated Circuit Having a Micromagnetic Device,” issued Aug. 27, 2002,which is incorporated herein by reference, describe a micromagnetic coreformed on a semiconductor substrate by depositing Permalloy (typically80% nickel and 20% iron) in the presence of a magnetic field. Dimensionsof the core are designed using conformal mapping techniques. Themagnetic field selectively orients the resulting magnetic domains in themicromagnetic core, thereby producing a magnetically anisotropic devicewith “easy” and “hard” directions of magnetization, and withcorresponding reduction in magnetic core losses at high switchingfrequencies compared to an isotropic magnetic device. Feygenson furtherdescribes depositing a thin chromium and silver film to form a seedlayer for further deposition of magnetic material to form a planarmagnetic core by an electroplating process that has good adhesion to aninsulating oxide layer that is formed on a semiconductor (or othersuitable) substrate. The chromium and silver seed layer is etched with aceramic ammonium nitrate reagent without substantial effect on themagnetic alloy.

Filas, et al., in U.S. Pat. No. 6,624,498, entitled “MicromagneticDevice Having Alloy of Cobalt, Phosphorus and Iron,” issued Sep. 23,2003, which is incorporated herein by reference, describe a planarmicromagnetic device formed with a photo resist that is etched butretained between magnetic core and conductive copper layers. Themicromagnetic device includes a planar magnetic core of an amorphouscobalt-phosphorous-iron alloy, wherein the fractions of cobalt andphosphorus are in the ranges of 5-15% and 13-20%, respectively, and ironbeing the remaining fraction. Magnetic saturation flux densities in therange of 10-20 Kilogauss (“kG”) are achievable, and low loss in themagnetic core structure is obtained by depositing multiple insulatedmagnetic layers, each with a thickness less than the skin depth at theswitching frequency of the power converter [e.g., about 2.5 micrometers(“μm”) at 8 megahertz (“MHz”) for relative permeability of μ_(r)=1000].Thin seed layers of titanium and gold are deposited before performing anelectroplating process for the magnetic core, and are oxidized andetched without substantial degradation of exposed adjacent conductivecopper layers. The planar magnetic core is formed using anelectroplating process in an electrolyte with pH about three containingascorbic acid, sodium biphosphate, ammonium sulfate, cobalt sulfate, andferrous sulfate. As described by Kossives, et al., in U.S. Pat. No.6,649,422, entitled “Integrated Circuit Having a Micromagnetic Deviceand a Method of Manufacture Therefore,” issued Nov. 18, 2003, which isincorporated herein by reference, an integrated device formed on asemiconductor substrate includes a planar magnetic device, a transistor,and a capacitor so that the principal circuit elements of a powerconverter can be integrated onto a single semiconductor chip.

Thus, although substantial progress has been made in development oftechniques for production of a highly integrated power converter that isformed on a single chip, these processes are not suitable formanufacturing an integrated micromagnetic device in substantial numbersand with the process yields and repeatability necessary to produce thereliability and cost for an end product. In particular, electrolytes forforming magnetic and conductive layers should have sufficient life forcontinued operation in an ongoing manufacturing environment. Theelectroplating processes should repeatably deposit uniformly thicklayers of high-performance magnetic materials with consistent andpredictable properties. In addition, the high-frequency ac properties ofa micromagnetic core so deposited should exhibit low and repeatable coreloss. Similarly, the conductive windings should exhibit low andrepeatable high-frequency resistance.

Accordingly, what is needed in the art is a micromagnetic device andmethod of producing the same that can be manufactured in high volume andwith low cost in a continuing production environment, the necessaryelectroplating tools and electrolytes therefor, and an electroplateablemagnetic alloy with high performance magnetic characteristics atswitching frequencies that may exceed one megahertz, that overcome thedeficiencies in the prior art. In addition, the resulting micromagneticdevice should be dimensionally stable with low internal stresses so thatthe micromagnetic device remains sufficiently planar to support furtherprocessing steps.

SUMMARY OF THE INVENTION

These and other problems are generally solved or circumvented, andtechnical advantages are generally achieved, by advantageous embodimentsof a method of processing a substrate with a conductive film formedthere over. In one embodiment, the method of processing the substrateincludes reducing a temperature of the substrate to astress-compensating temperature, and maintaining the temperature of thesubstrate at the stress-compensating temperature for a period of time.The method also includes increasing the temperature of the substrateabove the stress-compensating temperature.

In another aspect, a method of forming a micromagnetic device includesforming an insulating layer over a substrate, forming a conductivewinding layer over the insulating layer, forming another insulatinglayer over the conductive winding layer, and forming a magnetic corelayer over the another insulating layer. The method also includesreducing a temperature of the micromagnetic device to astress-compensating temperature, maintaining the temperature of themicromagnetic device at the stress-compensating temperature for a periodof time, and increasing the temperature of the micromagnetic deviceabove the stress-compensating temperature.

The foregoing has outlined rather broadly the features and technicaladvantages of the invention in order that the detailed description ofthe invention that follows may be better understood. Additional featuresand advantages of the invention will be described hereinafter which formthe subject of the claims of the invention. It should be appreciated bythose skilled in the art that the conception and specific embodimentdisclosed may be readily utilized as a basis for modifying or designingother structures or processes for carrying out the same purposes of theinvention. It should also be realized by those skilled in the art thatsuch equivalent constructions do not depart from the spirit and scope ofthe invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the invention, reference is nowmade to the following descriptions taken in conjunction with theaccompanying drawings, in which:

FIG. 1 illustrates a block diagram of an embodiment of a power converterconstructed according to the principles of the present invention;

FIG. 2 illustrates a schematic diagram of an embodiment of a power trainof a power converter constructed according to the principles of thepresent invention;

FIG. 3 illustrates a plan view of a micromagnetic device formedaccording to the principles of the present invention;

FIGS. 4 to 28 illustrate cross sectional views of a method of forming amicromagnetic device constructed according to the principles of thepresent invention;

FIG. 29 illustrates a cross sectional view of an embodiment of amicromagnetic device constructed according to the principles of thepresent invention;

FIG. 30 illustrates a scanning electron microscope view of amicromagnetic device constructed according to the principles of thepresent invention;

FIG. 31 illustrates a partial cross-sectional view of magnetic corelayers of a magnetic core of a micromagnetic device constructedaccording to the principles of the present invention;

FIG. 32 illustrates an elevational view of an embodiment of anelectroplating tool constructed according to the principles of thepresent invention; and

FIG. 33 illustrates a diagram of a portion of an embodiment of anelectroplating tool constructed according to the principles of thepresent invention.

Corresponding numerals and symbols in the different figures generallyrefer to corresponding parts unless otherwise indicated, and may not beredescribed in the interest of brevity after the first instance. Thefigures are drawn to clearly illustrate the relevant aspects of thepreferred embodiments.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of embodiments are discussed in detail below. Itshould be appreciated, however, that the invention provides manyapplicable inventive concepts that can be embodied in a wide variety ofspecific contexts. The specific embodiments discussed are merelyillustrative of specific ways to make and use the invention, and do notlimit the scope of the invention.

The invention will be described with respect to exemplary embodiments ina specific context, namely, a micromagnetic device, method of formingthe same and a power converter employing the same. Additionally, anelectroplating tool and electrolyte employable for constructing amagnetic core layer of the micromagnetic device will also be describedherein. Also, a method of processing a substrate and micromagneticdevice to relieve stress induced by a conductive film will be describedherein.

Referring initially to FIG. 1, illustrated is a block diagram of anembodiment of a power converter including an integrated micromagneticdevice constructed according to the principles of the invention. Thepower converter includes a power train 110 coupled to a source ofelectrical power (represented by a battery) for providing an inputvoltage V_(in), for the power converter. The power converter alsoincludes a controller 120 and a driver 130, and provides power to asystem (not shown) such as a microprocessor coupled to an outputthereof. The power train 110 may employ a buck converter topology asillustrated and described with respect to FIG. 2 below. Of course, anynumber of converter topologies may benefit from the use of an integratedmicromagnetic device constructed according to the principles of theinvention and are well within the broad scope of the invention.

The power train 110 receives an input voltage V_(in) at an input thereofand provides a regulated output characteristic (e.g., an output voltageV_(out)) to power a microprocessor or other load coupled to an output ofthe power converter. The controller 120 may be coupled to a voltagereference representing a desired characteristic such as a desired systemvoltage from an internal or external source associated with themicroprocessor, and to the output voltage V_(out) of the powerconverter. In accordance with the aforementioned characteristics, thecontroller 120 provides a signal S_(PWM) to control a duty cycle and afrequency of at least one power switch of the power train 110 toregulate the output voltage V_(out) or another characteristic thereof byperiodically coupling the integrated magnetic device to the inputvoltage V_(in).

In accordance with the aforementioned characteristics, a drive signal(s)[e.g., a first gate drive signal PG with duty cycle D functional for aP-channel MOSFET (“PMOS”) power switch and a second gate drive signal NGwith complementary duty cycle 1-D functional for a N-channel MOSFET(“NMOS”) power switch] is provided by the driver 130 to control a dutycycle and a frequency of one or more power switches of the powerconverter, preferably to regulate the output voltage V_(out) thereof.For a better understanding of power converters and related systems andcomponents therein, see U.S. Pat. No. 7,038,438, entitled “Controllerfor a Power Converter and a Method of Controlling a Switch Thereof,” toDwarakanath, et al., issued May 2, 2006, U.S. Pat. No. 7,019,505,entitled “Digital Controller for a Power Converter Employing SelectablePhases of a Clock Signal,” to Dwarakanath, et al., issued Mar. 28, 2006,U.S. Patent Application Publication No. 2005/0168203, entitled “Driverfor a Power Converter and a Method of Driving a Switch Thereof,” toDwarakanath, et al., published Aug. 4, 2005, U.S. Patent ApplicationPublication No. 2005/0167756, entitled “Laterally Diffused Metal OxideSemiconductor Device and Method of Forming the Same,” to Lotfi, et al.,published Aug. 4, 2005 (now U.S. Pat. No. 7,230,203, issued Jun. 12,2007), and U.S. Pat. No. 7,214,985, entitled “Integrated CircuitIncorporating Higher Voltage Devices and Low Voltage Devices Therein,”to Lotfi, et al., issued May 8, 2007, which are incorporated herein byreference.

Turning now to FIG. 2, illustrated is a schematic diagram of anembodiment of a power train of a power converter including an integratedmicromagnetic device constructed according to the principles of theinvention. While in the illustrated embodiment the power train employs abuck converter topology, those skilled in the art should understand thatother converter topologies such as a forward converter topology or anactive clamp topology are well within the broad scope of the invention.

The power train of the power converter receives an input voltage V_(in)(e.g., an unregulated input voltage) from a source of electrical power(represented by a battery) at an input thereof and provides a regulatedoutput voltage V_(out) to power, for instance, a microprocessor at anoutput of the power converter. In keeping with the principles of a buckconverter topology, the output voltage V_(out) is generally less thanthe input voltage V_(in) such that a switching operation of the powerconverter can regulate the output voltage V_(out). A main power switchQ_(main), (e.g., a PMOS switch) is enabled to conduct by a gate drivesignal PG for a primary interval (generally co-existent with a dutycycle “D” of the main power switch Q_(main),) and couples the inputvoltage V_(in) to an output filter inductor L_(out), which may beadvantageously formed as a micromagnetic device. During the primaryinterval, an inductor current I_(out) flowing through the output filterinductor L_(out) increases as a current flows from the input to theoutput of the power train. An ac component of the inductor currentI_(Lout) is filtered by an output capacitor C_(out).

During a complementary interval (generally co-existent with acomplementary duty cycle “1-D” of the main power switch Q_(main)), themain power switch Q_(main) is transitioned to a non-conducting state andan auxiliary power switch Q_(aux) (e.g., an NMOS switch) is enabled toconduct by a gate drive signal NG. The auxiliary power switch Q_(aux)provides a path to maintain a continuity of the inductor currentI_(Lout) flowing through the micromagnetic output filter inductorL_(out). During the complementary interval, the inductor currentI_(Lout) through the output filter inductor L_(out) decreases. Ingeneral, the duty cycle of the main and auxiliary power switchesQ_(main), Q_(aux) may be adjusted to maintain a regulation of the outputvoltage V_(out) of the power converter. Those skilled in the art shouldunderstand, however, that the conduction periods for the main andauxiliary power switches Q_(main), Q_(aux) may be separated by a smalltime interval to avoid cross conduction therebetween and beneficially toreduce the switching losses associated with the power converter.

Turning now to FIG. 3, illustrated is a plan view of a micromagneticdevice formed according to the principles of the invention. Themicromagnetic device illustrated herein is an inductor, such as theinductor L_(out) illustrated and described with reference to FIG. 2,that provides an inductance in the range 400-800 nanohenries (“nH”) andcan conduct a current of approximately one ampere without substantiallysaturating the magnetic core thereof. The micromagnetic device is formedwith a height of about 150 μm over a substrate such as a siliconsubstrate. In alternative embodiments, the substrate may be formed ofglass, ceramic, or various semiconductor materials.

In an advantageous embodiment, the substrate is substantiallynonconductive, wherein currents induced in the substrate byhigh-frequency electromagnetic fields produced by the micromagneticdevice do not produce substantial losses in comparison with otherparasitic losses inherent within the micromagnetic device. The magneticand conductive layers of the micromagnetic device are constructed sothat it can support a power converter switching frequency of 5-10 MHzwithout substantial loss in copper conductors or in magnetic corepieces. In an integrated point-of-load power converter to be describedhereinbelow, the area of the micromagnetic device is roughly comparableto the area of the semiconductor power switches therein, such as thepower switches Q_(main), Q_(aux) illustrated and described withreference to FIG. 2, and the associated integrated control circuits of apower converter employing the same. In an advantageous embodiment, themicromagnetic device is formed on a separate substrate from anintegrated control circuit and the semiconductor power switches. Itshould be understood, however, that the micromagnetic device may beformed on the same substrate as power semiconductor switches and anintegrated control circuit. In a related embodiment, the micromagneticdevice may be formed over the semiconductor devices on the samesubstrate.

The micromagnetic device preferably includes iron-cobalt-phosphorusalloy magnetic core pieces 301, 302 and includes gaps 305, 306. Anexemplary iron-cobalt-phosphorous alloy will be described in more detailbelow. In the illustrated embodiment, the gaps 305, 306 are of lengthabout 10 μm. A copper winding 307 encircles the magnetic core pieces301, 302. Terminal pads (such as first and second terminal pads 303,304) provide an interconnection to the winding 307 for wire bonds orsolder bumps. Three terminal pads are illustrated herein.

The second terminal pad 304 is coupled to and provides a terminal forthe winding 307. As illustrated in FIG. 3, the first terminal pad 303 isnot coupled to the winding 307, but provides a location for three-pointmechanical support of the micromagnetic device. In an alternativeembodiment, the first terminal pad 303 may be used to provide a tappedconnection to the winding 307, thereby forming a tapped inductor. Afourth terminal pad (not shown) may also be provided in the lowerleft-hand corner of the micromagnetic device so that the winding 307 maybe separated into two dielectrically isolated portions to form anisolating transformer, wherein the top portion of the winding 307 iscoupled to the top two terminal pads, and the bottom portion of thewinding 307 is coupled to the bottom two terminal pads. A dotted line308 illustrates the approximate location of an elevation view of themicromagnetic device that will be used in FIGS. 4 to 28 to illustrate amethod of forming the micromagnetic device. It should be understood thatthe dimensions illustrated with respect to the micromagnetic device ofFIG. 3 are provided for illustrative purposes only.

The sequence of steps to produce a micromagnetic device formed accordingto the principles of the invention will now be described. In theinterest of brevity, the details of some processing steps well known inthe art may not be included in the descriptive material below. Forexample, without limitation, cleaning steps such as using deionizedwater or a reactive ionizing chamber may not be described, generallybeing ordinary techniques well known in the art. The particularconcentration of reagents, the exposure times for photoresists, generalprocessing temperatures, current densities for electroplating processes,chamber operating pressures, chamber gas concentrations, radiofrequencies to produce ionized gases, etc., are often ordinarytechniques well-known in the art, and will not always be included in thedescription below. Similarly, alternative reagents and processingtechniques to accomplish substantially the same result, for example, thesubstitution of chemical-vapor deposition for sputtering, etc., will notbe identified for each processing step, and such substitutions areincluded within the broad scope of the invention. The dimensions andmaterial compositions of the exemplary embodiment described below alsomay be altered in alternative designs to meet particular designobjectives, and are included within the broad scope of the invention.

Turning now to FIGS. 4 to 28, illustrated are cross sectional views of amethod of forming a micromagnetic device constructed according to theprinciples of the invention. Beginning with FIG. 4, illustrated is asubstrate 401, approximately 1 mm thick, formed from silicon. A firstphoto resist layer 404 is spun on to a top surface of the substrate 401and patterned to form an aperture 407, exposing thereby a portion of thesubstrate 401 for further processing. In the illustrated embodiment,photoresist AZ4330, such as available from AZ Electronic Materials USACorp., Branchburg, N.J., is spun on using standard photolithographytechniques to form a three μm thick patterned film.

Turning now to FIG. 5, a trench 410 is etched into the substrate 401 toform a depressed area about 50 μm deep that will accommodate aconductive winding layer, preferably copper, formed in a laterprocessing step for a conductive winding. The trench 410 is formed usinga deep reactive ion etch (“DRIE”) such as the Bosch process. The Boschprocess, as is well known in the art, uses a sequence of gases such assulfur hexafluoride (“SF₆”) followed by octafluorocyclobutane (“C₄F₈”)to produce a highly anisotropic etching process that removes exposedportions of the substrate 401 at the bottom of the trench 410. The widthof the trench 410 illustrated in FIG. 5 is about 465 μm, and thedimension of the trench 410 out of the plane of the FIGURE is about 70μm. The first photoresist layer 404 is then removed using techniqueswell-known in the art.

Turning now to FIG. 6, an insulating layer [e.g., a thermal silicondioxide (“SiO₂”) insulating layer] is deposited onto each side of thesubstrate 401, including the trench 410, as illustrated by first andsecond insulating layers 412, 414. An alternative process for depositingan insulating layer can use a chemical vapor deposition process. In anadvantageous embodiment, the thickness of the first and secondinsulating layers 412, 414 is about five μm on each side of thesubstrate 401. The thickness of the first and second insulating layers412, 414 affects residual mechanical stress due to differential thermalexpansion of conductive, magnetic, and other layers during deviceprocessing steps. The removal of the first insulating layer 412 is acomponent affecting residual die stress after completion ofmicromagnetic device processing steps. The thickness of the first andsecond insulating layers 412, 414 can be adjusted using simulation orexperimental techniques to produce a die with low residual mechanicalstress after completion of micromagnetic device processing.

Turning now to FIG. 7, a first adhesive layer 415 of titanium (“Ti”) orchromium (“Cr”) is sputtered onto the top surface of the micromagneticdevice above the second insulating layer 414. Deposition of the firstadhesive layer 415 is followed by deposition of a first seed layer 418(e.g., gold or copper) for a later electroplating step. The first seedlayer 418 forms a conductive layer onto which a winding will bedeposited in a later processing step. The thickness of the firstadhesive layer 415 is preferably about 200 angstroms (“Å”), and thethickness of the overlying first seed layer 418 is preferably about 2000Å.

Turning now to FIG. 8, a second photoresist layer 420 is deposited abovethe first seed layer 418. The second photoresist layer 420 is spun onand patterned to form an aperture substantially above the trench 410,exposing thereby a portion of the first seed layer 418 therebelow. Inthe illustrated embodiment, the second photoresist layer 420 is NR9 8000from Futurrex Inc., of Franklin, N.J., and, using standardphotolithography techniques, is spun on to produce about a 15 μm thickpatterned film.

Turning now to FIGS. 9 and 10, a first conductive winding layer 423 toform a first winding section for the micromagnetic device iselectroplated onto the exposed first seed layer 418, preferably using anelectrolyte and electroplating process as described later hereinbelow.In an advantageous embodiment, the first winding section is formed fromcopper. As illustrated in FIG. 9, the first conductive winding layer 423is deposited up to and above the top surface of the second photoresistlayer 420. With respect to FIG. 10, the second photoresist layer 420illustrated previously is stripped off a top surface of themicromagnetic device using conventional photoresist strippingtechniques.

Turning now to FIG. 11, the top surface of the micromagnetic device ispolished using a conventional chemical-mechanical polishing (“CMP”)process as is known in the art. The result of this process produces asubstantially smooth and level surface on the top surface of themicromagnetic device exposing a top surface of the first conductivewinding layer 423 and a portion of the second insulating layer 414.

Turning now to FIG. 12, a second adhesive layer 425 (e.g., titanium orchromium, approximately 1000 Å thick) is sputtered onto the top surfaceof the micromagnetic device followed by a sputtered third insulatinglayer 430 (e.g., silicon dioxide) approximately 5000 Å thick. Analternative process for depositing the third insulating layer 430 uses achemical vapor deposition process.

Turning now to FIG. 13, a third adhesive layer 433 of titanium orchromium, preferably 300 Å thick, is deposited by sputtering followed bya second seed layer 435 (e.g., gold or copper) that is 1000 Å thick. Athird photoresist layer 440 is then deposited above the second seedlayer 435 and patterned with standard photolithography techniques toform a 10 μm thick first photoresist aperture 445 therein exposingportions of the second seed layer 435. The first photoresist aperture445 is used to define a shape for a first magnetic core layer includingan alloy such as an iron-cobalt alloy that is subsequentlyelectroplated. In the illustrated embodiment, the third photoresistlayer 440 is AZ9260 from AZ Electronic Materials USA Corp., Branchburg,N.J.

Turning now to FIG. 14, a first magnetic core layer 450 formed from aniron-cobalt alloy is electroplated through the first photoresistaperture 445 illustrated in FIG. 13. In this embodiment, the thicknessof the iron-cobalt alloy is about six μm. Following the electroplatingprocess for the iron-cobalt alloy, the substrate is rinsed with carbondioxide (“CO₂”)-saturated, de-ionized water and immersed in anelectrolyte (e.g., a nickel electrolyte) to form a first protectivelayer 455 (e.g., a thin nickel protective layer at about 250-300 Å) overthe first magnetic core layer 450.

Turning now to FIG. 15, the third photoresist layer 440 is stripped offthe top surface of the micromagnetic device using conventionalphotoresist stripping techniques. A fourth adhesive layer 457 oftitanium or chromium is deposited onto the first protective layer 455,followed by a sputter-deposited fourth insulating layer 460 of aluminumoxide or silicon dioxide at about 500 Å.

Turning now to FIG. 16, preparation for a second magnetic core layer ofan iron-cobalt alloy electroplating process begins with the sputterdeposition of a fifth adhesive layer 462 followed by a third seed layer464 of gold or copper, preferably similar to those used under the firstmagnetic core layer 450 (e.g., 300 Å of titanium or chromium followed by1000 Å of gold or copper). A fourth photoresist layer 465 is depositedabove the third seed layer 464 and patterned with standardphotolithographic techniques to form a 15 μm thick second photoresistaperture 467 employable to define a shape of the second magnetic corelayer that is to be electroplated thereabout. The second photoresistaperture 467 exposes the third seed layer 464. In the illustratedembodiment, the fourth photoresist layer 465 is AZ9260 from AZElectronic Materials USA Corp., Branchburg, N.J.

Turning now on FIGS. 17 and 18, a second magnetic core layer 470 of aniron-cobalt alloy is electroplated through the second photoresistaperture onto the third seed layer 464. In the illustrated embodiment,the thickness of the iron-cobalt alloy is about six μm. Following theelectroplating process for the iron-cobalt alloy, the substrate isrinsed with carbon dioxide (“CO₂”)-saturated, de-ionized water andimmersed in an electrolyte (e.g., a nickel electrolyte) to form a secondprotective layer 472 (e.g., a thin nickel protective layer at about250-300 Å) over the second magnetic core layer 470. With respect to FIG.18, the fourth photoresist layer 465 is stripped off the top surface ofthe micromagnetic device using conventional photoresist strippingtechniques. While the illustrated embodiment includes two magnetic corelayers, it should be understood that the aforementioned process may berepeated any number of times to provide the desired number of magneticcore layers as dictated by a particular application.

Turning now to FIG. 19, a sixth adhesive layer 474 (e.g., titanium orchromium at about 300 Å) is deposited by sputtering over the surface ofthe micromagnetic device. The sixth adhesive layer 474 is followed bysputter-deposition of a fifth insulating layer 476 over the top surfaceof the sixth adhesive layer 474 at approximately 5000 Å thick. The fifthinsulating layer 476 includes aluminum oxide or silicon dioxide at about500 Å, an insulation polymer, a photoresist, or polyimide. Analternative process for depositing a silicon dioxide or other insulatinglayer uses a chemical-vapor deposition process.

Thus, the first and second magnetic core layers 450, 470 areelectroplated between the third and fifth insulating layers 430, 476.The iron-cobalt alloy magnetic core layers preferably alternate withlayers of nickel, an adhesion layer, an insulation layer, a furtheradhesion layer, and a seed layer. An exemplary thickness of theiron-cobalt alloy layers is six μm, which is approximately one skindepth for a switching frequency of 10 MHz. The thickness of theiron-cobalt alloy layers is typically constrained to be relatively thinsuch as six μm to reduce core loss due to induced currents in thesemagnetically permeable and electrically conductive layers at theswitching frequency of a power converter or other end product. In anexemplary design, six magnetic core layers are deposited with fiveinterposed insulating layers, etc.

Turning now to FIG. 20, vias 478 are opened through the micromagneticdevice to the first conductive winding layer 423. The vias 478 areformed by depositing a photoresist such as AZ4620, by AZ ElectronicMaterials USA Corp., Branchburg, N.J., by spinning, curing, patterning,and processing to expose apertures to down through the second adhesivelayer 425 and the third insulating layer 430. The exposed portions ofthe micromagnetic device are then etched down to the first windingsection 423 using a buffered oxide etch, which is typically a blend of49% hydrofluoric acid (“HF”) and 40% ammonium fluoride (“NH₄F”) invarious predetermined ratios, after cleaning the substrate withdeionized water, using techniques well known in the art.

Turning now to FIG. 21, a seventh adhesive layer 480 (e.g., titanium orchromium) followed by a fourth seed layer 482 are deposited across thetop surface of the micromagnetic device onto which a conductive layerthereof will be electrodeposited in a later processing step. The fourthseed layer 482 is formed by sequentially sputtering thin sublayers ofgold (at about 500 Å) and/or copper (at about 2000 Å).

Turning now to FIG. 22, a fifth photoresist layer 484 is deposited abovethe fourth seed layer 482. The fifth photoresist layer 484 is spun onand patterned to form apertures for a conductive layer to beelectrodeposited in a later processing step that forms a portion of awinding of the micromagnetic device. In the illustrated embodiment, thefifth photoresist layer 484 is AZ4620, by AZ Electronic Materials USACorp., Branchburg, N.J. and is spun on and soft baked using amulti-spin/single exposure technique to produce a 50 μm thickphotoresist film. The first spin is followed by a soft bake at 80° C. ona hot plate for approximately five minutes. Then a second layer ofphotoresist is spun on and a second bake at 120° C. for five minutes isperformed to outgas solvents therefrom. Then an ultraviolet exposure anda developing step define the top conductive patterns in the fifthphotoresist layer 484.

Turning now to FIG. 23, a second conductive winding layer 486 of themicromagnetic device is electrodeposited over the fourth seed layer 482to form a second winding section. In an advantageous embodiment, thesecond winding section 486 is formed from copper. The electrodepositionprocess is preferably performed using an electrolyte as described below.The first and second winding sections form a winding for themicromagnetic device.

Turning now to FIG. 24, the fifth photoresist layer 484 is stripped offthe top surface of the micromagnetic device using conventionalphotoresist stripping techniques, exposing portions of the fourth seedlayer 482 previously covered by the fifth photoresist layer 484.Thereafter, exposed portions of the fourth seed layer 482 are removedvia a sulfuric acid etch and exposed portions of the seventh adhesivelayer 480 are removed via a hydrofluoric acid etch.

Turning now to FIG. 25, an eighth adhesive layer 488 of titanium issputtered onto the top surface of the micromagnetic device at about 2000Å. The eighth adhesive layer 488, after etching, will provide amechanical base for a solder-ball capture in a later processing step.

Turning now to FIG. 26, a photoresist layer (not shown) is depositedover the eighth adhesive layer 488. The photoresist layer is spun on andpatterned using conventional processing techniques to expose portions ofthe eighth adhesive layer 488 that are then removed by etching to formapertures for solder balls or other interconnect to be deposited in alater processing step. In this exemplary embodiment, the photoresistlayer is AZ4400 from AZ Electronic Materials USA Corp., Branchburg, N.J.After forming the apertures in the photoresist layer, the exposedportions of the underlying eighth adhesive layer 488 are etched down tothe second winding section 486 using a hydrofluoric acid etch. Theresult is to produce apertures 490 for solder balls in the eighthadhesive layer 488.

Turning now to FIG. 27, the first insulating layer 412 is removed bybackgrinding, using techniques well understood in the art. The originalthickness of the substrate 401 was about one mm, which is now grounddown to approximately 200 μm to accommodate thinner packaging andimproved heat transfer of the micromagnetic device. In the backgrindingprocess, the layer of silicon dioxide, which forms the first insulatinglayer 412, is removed with an adjoining portion of the substrate 401.The process of thinning the substrate 401 and removing the firstinsulating layer 412 is a stress-relieving step that accommodates andrelieves a substantial portion of the strain that inherently resultsfrom previous processing steps that deposited the conductive andmagnetic alloy structures for the micromagnetic device.

Turning now to FIG. 28, interconnects 495 (e.g., solder balls) for laterinterconnection of the micromagnetic device to external circuitry aredropped into the apertures 490 that were formed in the eighth adhesivelayer 488. In an advantageous embodiment, the solder balls 495 arelead-free. The solder balls 495 may be placed by positioning a mask onthe top surface of the micromagnetic device. The mask is formed withappropriately sized and located apertures that are above the desiredsolder-ball locations. A quantity of solder balls 495 is poured onto themask, and the assembly is shaken to cause the solder balls 495 to dropinto the mask apertures. The remaining solder balls 495 are poured off.In an alternative process, solder balls 495 may be placed using aplacing mechanism employing a vacuum-operated ball-placing tool. As afurther alternative for later interconnection of the micromagneticdevice, a solder layer can be deposited into the apertures 490 formed inthe eighth adhesive layer 488 using an electroplating process. FIG. 28also illustrates sawing lines (e.g., sawing line location 497) for diesingulation as necessary.

Turning now to FIG. 29, illustrated is a cross sectional view of anembodiment of a micromagnetic device constructed according to theprinciples of the present invention. In the present embodiment, somelayers have been omitted or combined into a single layer for purposes ofillustration. The micromagnetic device is formed on a substrate 505(e.g., silicon) and includes a first insulating layer 510 (e.g., silicondioxide) formed thereover. Following an electroplating process to form atrench in a center region of the substrate 505, an adhesive layer (e.g.,titanium or chromium) and a first seed layer 515 (e.g., gold or copper)are formed over the first insulating layer 510. Additionally, a firstconductive winding layer 520 of, without limitation, copper, is formedin the trench that forms a first section of a winding for themicromagnetic device.

An adhesive layer (e.g., titanium or chromium) and a second insulatinglayer 525 (e.g., silicon dioxide) is formed above the first conductivewinding layer 520. The micromagnetic device also includes first andsecond magnetic core layers 530, 540 with a third insulating layer 535therebetween in a center region of the substrate 505 above the firstconductive winding layer 520. The first and second magnetic core layers530, 540 are typically surrounded by an adhesive layer, seed layer andprotection layer as set forth below with respect to FIG. 31. Also, anadhesive layer may be formed prior to forming the third insulating layer535.

An adhesive layer (e.g., titanium or chromium) and a fourth insulatinglayer 545 (e.g., silicon dioxide) are formed above the second magneticcore layer 540 in the center region of the substrate 505 and over thesecond insulating layer 525 laterally beyond the center region of thesubstrate 505. An adhesive layer (e.g., titanium or chromium) and asecond seed layer 550 (e.g., gold or copper) are formed above the fourthinsulating layer 545 in the center region of the substrate 505 and invias down to the first conductive winding layer 520 about the centerregion of the substrate 505. A second conductive winding layer 555 isformed above the second seed layer 550 and in the vias to the firstconductive winding layer 520. The second conductive winding layer 555 isformed of, without limitation, copper and forms a second section of awinding for the micromagnetic device. Thus, the first conductive windinglayer 520 and the second conductive winding layer 555 form the windingfor the micromagnetic device.

An adhesive layer 560 (e.g., titanium) is formed above the secondconductive winding layer 555 in the center region of the substrate 505and over the fourth insulating layer 545 laterally beyond the centerregion of the substrate 505. Solder balls 565 are formed in apertures inthe adhesive layer 560.

Turning now to FIG. 30, illustrated is a scanning electron microscopeview of a micromagnetic device (e.g., an inductor) constructed accordingto the principles of the invention. The inductor is formed with alayered magnetic core 610 on a silicon substrate 620. An air gap 630 oflength 10 μm between the magnetic core sections is visible in themicrophotograph. A copper conductive winding 640 is formed around thelayered magnetic core 610. A 200 μm scale is visible in the lowerportion of the microphotograph to provide a reference for feature sizes.Although the formation of a micromagnetic device has been describedherein using an iron-cobalt alloy, in an advantageous embodiment, themicromagnetic device employs other materials such as aniron-cobalt-phosphorus alloy as described below.

Turing now to FIG. 31, illustrated is a partial cross-sectional view ofmagnetic core layers of a magnetic core of a micromagnetic deviceconstructed according to the principles of the present invention. Asmentioned above, while the present embodiment illustrates two magneticcore layers, the principles of the present invention are not so limited.The first and second magnetic core layers (designated “Layer 1” and“Layer 2”) include an adhesion layer (designated “Adhesive Layer”) of,without limitation, titanium or chromium and a seed layer (designed“Seed Layer”) of, without limitation, gold or copper. The first andsecond magnetic core layers also include a magnetic core layer(designated “Magnetic Core Layer”) of, without limitation, aniron-cobalt-phosphorus alloy and a protective layer (designated“Protective Layer”) of, without limitation, nickel. First and secondinsulating layers (designated “Insulating Layer 1” and “Insulating Layer2”) include an adhesion layer (designated “Adhesive Layer”) of, withoutlimitation, titanium or chromium and an insulting layer (designated“Insulating Layer”) of, without limitation, silicon dioxide or aluminumoxide. The sequence of magnetic core layers insulation layers can berepeated as needed to form the desired number of magnetic core layers.

Thus, a sequence of steps has been introduced for forming amicromagnetic device with improved magnetic characteristics usingprocesses that readily accommodate high-volume production. Although theexemplary device that was described with reference to FIG. 4, et seq.,is an inductor, straightforward alterations to the process can bereadily made by one with ordinary skill in the art to form a transformerwith dielectrically isolated windings.

In an exemplary embodiment, the micromagnetic device is formed on asubstrate and includes a first insulating layer (e.g., silicon dioxide)formed above the substrate (e.g., silicon), and a first seed layer(e.g., gold or copper) formed above the first insulating layer. Themicromagnetic device also includes a first conductive winding layer(e.g., gold) selectively formed above the first seed layer, a secondinsulating layer (e.g., silicon dioxide) formed above the firstconductive winding layer, and a first magnetic core layer (e.g.,iron-cobalt alloy or an iron-cobalt-phosphorus alloy) formed above thesecond insulating layer. Thereabove, the micromagnetic device includes asecond magnetic core layer (e.g., iron-cobalt alloy or aniron-cobalt-phosphorus alloy) formed between third and fourth insulatinglayers (e.g., aluminum oxide, silicon dioxide, insulation polymer,photoresist or polyimide). The micromagnetic device further includes asecond seed layer (e.g., sublayers of gold and copper) formed above thefourth insulating layer, and a second conductive winding layer (e.g.,gold) formed above the second seed layer and in vias to the firstconductive winding layer. The first conductive winding layer and thesecond conductive winding layer form a winding for the micromagneticdevice. In an advantageous embodiment, a protective layer (e.g., nickel)may be formed above the first and second magnetic core layers.Additionally, an interconnect (e.g., solder balls) may be formed in anaperture of an adhesive layer formed above the second conductive windinglayer. Having introduced an exemplary micromagnetic device, method offorming the same and a power converter employing the same, we will nowturn our attention to an electroplating tool and electrolyte employablefor constructing the micromagnetic device.

Regarding the magnetic core layers, to provide an alloy with magneticproperties improved over alloys currently available, a ternary alloyincluding iron, cobalt, and phosphorous is introduced. Theiron-cobalt-phosphorous (“FeCoP”) alloy includes cobalt in the range of1.8-4.5 atomic percent (e.g., preferably 2.5 percent), phosphorus in therange of 20.1-30 atomic percent (e.g., preferably 22 percent), and ironincluding substantially the remaining proportion. The alloy preferablyincludes trace amounts of sulfur, vanadium, tungsten, copper, and/orcombinations thereof, with a concentration of each in the range of 1 to100 parts per million (“ppm”), to reduce stress and/or increaseresistivity compared to the basic ternary alloy without these traceelements. In the past, iron-cobalt-phosphorous alloys used higherproportions of cobalt (e.g., 5-15 atomic percent), and lower proportionsof phosphorous (e.g., 13-20 atomic percent), which do not provide theadvantageous high-frequency magnetic characteristics and otherproperties as described herein.

An iron-cobalt-phosphorous alloy employable with the magnetic corelayers of FIG. 4, et seq., advantageously sustains a magnetic saturationflux density of about 1.5-1.7 tesla (15,000-17,000 gauss), andaccommodates a power converter switching frequency of, withoutlimitation, 10 MHz with low loss when electroplated in layers four μmthick, each layer separated by a thin insulation layer (e.g., aluminumoxide and/or silicon dioxide). In comparison, soft ferrites of the pastcommonly used in the design of switch-mode power converters typicallysustain a magnetic saturation flux density of only about 0.3 tesla. Theiron-cobalt-phosphorous alloy described herein is readily adaptable to arepeatable and continuing manufacturing process, and can provide longoperational life in a typical application environment withoutsubstantial degradation of operating characteristics. Theiron-cobalt-phosphorous alloy can be electroplated with a sufficientlyhigh current density to accommodate a low-cost manufacturing operation.The iron-cobalt-phosphorous alloy can be readily electroplated inalternating layers with intervening insulating layers onto a surfacepatterned, such as with a photoresist, to produce a micromagnetic deviceoperable at a high switching frequency with a low level of powerdissipation.

Thus, a micromagnetic device formed with a ternary alloy with magneticproperties improved over those currently available, and related method,have been introduced herein formed over a substrate (e.g., silicon,glass, ceramic). In an advantageous embodiment, the new ternary alloyincludes iron, cobalt and phosphorous and the magnetic alloy is anamorphous or nanocrystalline magnetic alloy.

In one embodiment, the micromagnetic device includes a substrate and amagnetic core layer formed over the substrate from a magnetic alloy. Themicromagnetic device also includes an insulating layer formed over themagnetic core layer and another magnetic core layer formed over theinsulating layer from a magnetic alloy. At least one of the magneticalloys include iron, cobalt and phosphorous and a content of said cobaltis in the range of 1.8 to 4.5 atomic percent, a content of saidphosphorus is in the range of 20.1 to 30 atomic percent, and a contentof said iron is substantially a remaining proportion of said at leastone of said magnetic alloys.

Turning now to FIG. 32, illustrated is an elevational view of anembodiment of an electroplating tool constructed according to theprinciples of the invention. An electrolyte employable in theelectroplating tool is adaptable for the deposition of a magnetic alloyincluding ones of iron, cobalt and phosphorus with advantageous magneticproperties as described below. The electroplating tool includes anelectroplating cell 705 supplied with an electrolyte 710 from areservoir 715. The reservoir 715 contains the electrolyte 710 withchemical composition including phosphorous as described below. In theembodiment represented in FIG. 32, the combined volume of theelectrolyte 710 in the electroplating cell 705 and the reservoir 715 isapproximately 90 liters. The electrolyte 710 is pumped by a firstcirculating pump 720 from the reservoir 715 through a first tube 725 tothe electroplating cell 705, the flow of which is adjusted or regulatedby first and second valves 727, 729. The electrolyte 710 supplied by thefirst circulating pump 720 flows through nozzles 730 into theelectroplating cell 705 at a high flow rate to provide electrolyteagitation for electroplating uniformity. In an advantageous embodimentwherein a wafer (e.g., a six inch silicon wafer) is electroplated with amagnetic alloy, the flow rate of electrolyte 710 through apertures inthe nozzles 730 is adjusted to approximately 120 liters per minute. Theheight of the electrolyte 710 in the electroplating cell 705 iscontrolled by a partition 735 over which excess electrolyte 710 flowsbehind a wall 740, and is returned to the reservoir 715 through a secondtube 745.

The electrolyte 710 supplied to the electroplating cell 705 from thereservoir 715 through the first and second valves 727, 729 is dispersedthrough the electrolyte 710 already contained within the electroplatingcell 705 through the nozzles 730. In an advantageous embodiment, thenozzles 730 include apertures (e.g., apertures similar to apertures inan ordinary bathroom shower head) angularly disposed in six lines ofapertures oriented 60° apart.

Although the reservoir 715 and the electroplating cell 705 are fittedwith covers that can be opened to provide interior access, the reservoir715 and the electroplating cell 705 are typically closed andsubstantially sealed to the outside atmosphere during an electroplatingprocess. Lying in a lower position in the electroplating cell 705 and inreservoir 715 are first and second porous tubes 750, 752, respectively,through which an inert gas (e.g., nitrogen) flows from an inert gassource (e.g., a nitrogen source) during an electroplating operation.Small bubbles 755 (e.g., bubbles of nitrogen) are formed on the outersurface areas of the first and second porous tubes 750, 752 and aredispersed throughout the electrolyte 710 in each container. Oxygen inupper portions 755, 760, respectively, of the electroplating cell 705and the reservoir 715 is thereby exhausted to the outside atmosphere. Bythis means, the electrolyte 710 in the electroplating cell 705 and thereservoir 715 becomes substantially oxygen free, sustaining a dissolvedoxygen level less than ten ppb during an electroplating operation.

An anode 765 immersed for the electroplating process in the electrolyte710 is advantageously formed with an alloy of about four atomic percentcobalt and 96 atomic percent iron. A wafer or substrate 770 onto whichthe magnetic alloy is electroplated, is mounted on a magnet 775 which isrotated at a rotational rate, such as 100 revolutions per minute(“rpm”), by a motor 780. Rotation of the wafer 770 during theelectroplating process advantageously provides uniformity of coverage ofthe electroplated alloy thereon. The magnet 775 provides a magneticfield of approximately 1000-2000 gauss to orient the easy axis ofmagnetization of the electroplated material, forming thereby amagnetically anisotropic layer. The magnet 775 in the representationillustrated in FIG. 32 includes a rare earth permanent magnet. In analternative advantageous arrangement, the magnet 775 includes acurrent-carrying coil.

To maintain cleanliness during the electroplating process of theelectrolyte 710 contained in the electroplating cell 705 and in thereservoir 715, the electrolyte 710 in the reservoir 715 is recirculatedby a second circulating pump 785 through a microporous filter 787. In anadvantageous arrangement, the microporous filter 787 is a 0.2 μm filteror better. To further maintain electrolyte 710 cleanliness during theelectroplating process, metallic and other microscopic particles thatslough off the anode 765 are captured by encasing the anode 765 withinan envelope of a semipermeable membrane (see below). The filteredelectrolyte 710 from the microporous filter 787 flows into theelectroplating cell 705 and reservoir 715 through a third tube 790.Additionally, the proper pH is maintained by including pH-sensingelectrode(s) 792 in the electroplating cell 705 and/or the reservoir 715and adding acid, for example, 12% perchloric acid (“HClO₄”), or base, asneeded, with a metering pump control assembly 794 (e.g., including acontroller and a meter pump such as an Replenisher Model REPL50-5-B byIvek Corporation of North Springfield, Vt.) to the electroplating cell705 (via a fourth tube 796) and/or the reservoir 715 (via a fifth tube798) when the sensed pH rises above a threshold level.

Turning now to FIG. 33, illustrated is a diagram of a portion of anembodiment of an electroplating tool constructed according to theprinciples of the present invention. The present embodiment illustratesan anode 810 immersed in an electrolyte 820 and contained withinsemipermeable membrane 830 in accordance with an electroplating toolconstructed according to the principles of the invention. The filteredelectrolyte 820 from a microporous filter (see FIG. 32) flows into thevolume contained by the semipermeable membrane 830 through a first tube840 and is returned filtered to a reservoir (see FIG. 32) through asecond tube 850 and filter 860. In an advantageous embodiment, thefilter 860 includes a 0.2 μm filter or better. The cleanliness ofelectrolyte 820 in close proximity to a wafer (see FIG. 32) during acontinued electroplating operation is thereby preserved.

Several characteristics of the electroplating process are advantageouslyemployed to form a uniformly electroplated layer of a magnetic alloysuch as iron-cobalt-phosphorous alloy onto a surface of a wafer. First,a sufficiently high flow rate of the electrolyte is provided throughapertures in the nozzles to provide agitation of the electrolyte in theelectroplating cell (e.g., 120 liters per minute for a six inch wafer)such as by using a circulating pump (e.g., Baldor Model CL 3506 pump byBaldor Electric Company of Fort Smith, Arkansas). Second, the wafer isrotated (e.g., at 100 rpm) with a Leeson Model 985-616 D motor drive anda Leeson Speedmaster Controller Model 1740102.00 by Leeson ElectricCorporation of Grafton, Wis., onto which the electrolyte iselectroplated to provide uniformity of electroplating coverage. Third, asufficiently low level of dissolved oxygen in the electrolyte ismaintained to prevent oxidation of metallic species and other oxidizableelectrolyte components. A mechanism to maintain a low level of dissolvedoxygen is the bubbling of nitrogen (or other gas inert to chemicalspecies in the electroplating process) through the electrolyte to driveout residual dissolved oxygen. The dissolved oxygen level can bemonitored with a dissolved oxygen sensor, a monitoring process wellknown in the art, and the electroplating process can be interrupted whenthe dissolved oxygen level exceeds, for example, 10 parts per billion(“ppb”). Fourth, the pH level of the electrolyte may be maintained belowa level of, for instance, about three and preferably between about twoand three. The proper pH is maintained by including pH-sensingelectrodes in the electroplating cell and/or the reservoir (see FIG.32), and adding acid, for example, 12% perchloric acid (“HClO₄”), orbase, as needed, with metering pumps to the electroplating cell and/orthe reservoir when the sensed pH rises above a threshold level. Duringan ordinary electroplating process, the pH of the electrolyte increases,requiring continued addition of acid to maintain a particular pH level.

A fifth characteristic includes filtering the electrolyte in thereservoir at a sufficiently high rate with a microporous filter, such asa 0.2 μm filter or better, to remove microscopic particles produced bythe electroplating process such that a complete turn of the electrolytevolume in the electroplating cell and the reservoir may be one minute orless. Sixth, an anode should be provided of an iron-cobalt alloy,preferably about four atomic percent cobalt and 96 atomic percent ironalloy circular anode (e.g., an anode with about 130 millimeter diameterand 10 millimeter thick from Sophisticated Alloys, Inc. of Butler, Pa.Seventh, the anode should be enclosed within a semipermeable membrane inthe electroplating cell and the electrolyte should be filtered insidethe volume contained by the semipermeable membrane with a 0.2 μm filteror better, to prevent contamination of the electrolyte in the vicinityof the wafer being electroplated.

Thus, an electroplating tool and related method have been introducedthat accommodate electroplating onto a wafer a magnetically anisotropiclayer that can sustain a high magnetic field density without saturationand with low power dissipation at a high excitation frequency, themagnetically anisotropic layer advantageously including aniron-cobalt-phosphorous alloy. The process can produce an electroplatedlayer of an alloy such as an iron-cobalt-phosphorous alloy with minimalvariability over the wafer surface, and can sustain continued andrepeatable operation in a manufacturing environment.

In an advantageous embodiment, the electroplating tool includes areservoir having a cover configured to substantially seal the reservoirto an outside atmosphere during an electroplating process, and a poroustube couplable to an inert gas source configured to bubble an inert gasthrough an electrolyte containable therein. The electroplating tool alsoincludes an electroplating cell, coupled to the reservoir, havinganother cover configured to substantially seal the electroplating cellto an outside atmosphere during an electroplating process, and anotherporous tube couplable to an inert gas source configured to bubble aninert gas through an electrolyte containable therein. The electroplatingcell also includes an anode, encased in an envelope of a semipermeablemembrane, formed with an alloy of electroplating material, and a magnetconfigured to orient an axis of magnetization of the electroplatingmaterial for application to a wafer couplable thereto during anelectroplating process. The electroplating tool further includes acirculating pump coupled through a tube with a valve to theelectroplating cell and the reservoir. The circulating pump isconfigured to pump the electrolyte at a flow rate from the reservoirthrough the tube to the electroplating cell through nozzles therein. Theelectroplating tool still further includes another circulating pump andmicroporous filter coupled through a tube to the electroplating cell andthe reservoir. The another circulating pump is configured to pump theelectrolyte through the microporous filter from the reservoir throughthe tube to the electroplating cell and the reservoir.

The electrolyte chemistry and procedures to support electroplating amagnetic alloy such as an iron-cobalt-phosphorous alloy will now bedescribed. Additions to the material formulations described below toprovide further enhanced properties are contemplated and can be readilymade within the broad scope of the invention.

In electrolytes of the prior art employed to electroplate a magneticalloy such as Permalloy, the iron, cobalt, and other electrolytecomponents include aqueous sulfates with pH of approximately three, arenot buffered, and utilize an iron anode. The electrolyte as describedherein includes aqueous perchlorates of iron, cobalt, and otherelectrolyte components, with a pH of approximately two, is preferablybuffered, and uses an iron-cobalt alloy anode. In an advantageousembodiment, the pH is buffered in the range of about two to three, andpreferably less than about three. Other improvements of the electrolyteinclude neutralizing excess acid therein with ammonium bicarbonate, andusing a higher current density during an electroplating operation.

While the electrolytes of the prior art are unstable with continued use,the electrolyte as described herein is more robust. Higherelectroplating rates are possible using the electrolyte as describedherein, and are reproducible from substrate to substrate, which is notthe case using electrolytes of the prior art. By using an iron-cobaltalloy anode as described herein, the cobalt in the electrolyte iscontinuously replenished. Phosphorus is replenished by addingelectrolyte containing a phosphorous salt as described below.

Preparation of an exemplary 30-liter perchlorate electrolyte for aniron-cobalt-phosphorous ternary alloy will now be described. Theelectrolyte can be modified to add, without limitation, any or all of atrace amount (e.g., less than about 10 millimolar) of elements such assulfur, vanadium, tungsten, and copper.

The electrolyte (e.g., 24 liters (“L”) of water) is first deoxygenatedby bubbling nitrogen for 15-30 minutes. Chemicals are then addedpreferably in the order given below. An iron perchlorate is preferablyground into a powder before adding to a mixing tank since it is usuallylumpy as received from a vendor in bulk form. Since the iron in solutionis air sensitive, the solution should be prepared and stored under anitrogen or other atmosphere inert to the chemical constituents. Apolyethylene mixing tank with a recirculating pump and 0.2-μm or betterfilter may be used in an advantageous embodiment of the invention.

In an exemplary embodiment, the materials as listed below in Table Iinclude components to produce 30 L of electrolyte.

TABLE I CHEMICAL GRAMS TO MAKE 30 L pH Water, N₂ 24 kg (liters) ~7.0Ascorbic Acid 0.01M → 52.84 g  3.13 Sodium Hypophosphite 0.08M → 254.38g 3.07 NaH₂PO₂•H₂O Ammonium Perchlorate 0.50M → 1762.5 g 2.87 (NH₄)ClO₄Ferrous Perchlorate 0.65M → 7075.4 g 0.60 Fe(ClO₄)₂•6H₂O CobaltPerchlorate 0.006M → 66.01 g  0.60 CoClO₄•6H₂O

Due to excess perchloric acid in the (hydrated) ferrous perchlorate, theacid should be neutralized to raise the pH. Raising the pH should bedone slowly to avoid precipitation of iron hydroxides and oxidation toferric iron. In general, the pH should be kept less than about three.Ammonium bicarbonate solution (e.g., 150 grams/L) is added drop-wisewith vigorous stirring under nitrogen or other inert atmosphere. A whiteprecipitate may form when the neutralizing solution comes in contactwith the electrolyte, but if agitation is sufficient, it immediatelyredissolves without detrimental effect. A metering pump is preferablyused to add the neutralizing solution. The pump rate is initially set atabout 10 milliliters (“ml”) per minute.

A pH meter is used to monitor the pH in the mixing tank. The glasselectrode of the pH meter often requires changing the supportingelectrolyte therein from saturated potassium chloride (“KCl”) to onemolar ammonium perchlorate. Failure to follow this procedure willgenerally result in inaccurate pH readings. The meter is preferablycalibrated with pH equaling one and two buffers with measurement to anaccuracy of 0.01 unit. The pH rises slowly at first, then more rapidlywhen the pH is above one. When the pH reaches a target value of 1.95,water is added to bring the volume to 30 L.

Some brown precipitate remains in the solution in the mixing tank fromimpurities in the iron perchlorate, but it can be removed by filteringin an hour or less, depending on the pump rate in the mixing tank. Thesolution can be monitored spectrophotometrically to check for suspendedparticles and their concentrations. For example, at 400 nanometers(“nm”), an unfiltered solution (one centimeter path length) has abaseline absorbance of A=0.0400, and after filtering, A=0.0046. Iron iskept in the ferrous state by ascorbic acid, which needs periodicmonitoring. A Hach ascorbic acid test kit can be used to determine theascorbic acid concentration. The ascorbic acid absorbs strongly below300 nm, and a convenient measure of the “health” of the electrolyte isthe “wavelength cutoff,” λc, defined as the wavelength at which theabsorption of a one centimeter cm path is one. A newly prepared solutionhas λc=291 nm and, as the solution ages, the wavelength cutoff moves tolonger wavelengths. As long as λc<300 nm and the ascorbic acidconcentration is 0.01 M, the electrolyte should be useable. Without anitrogen atmosphere, ascorbic acid and iron oxidize, and the wavelengthcutoff shifts into the visible range rapidly.

For unpatterned substrates (i.e., for substrates that have not beenpatterned and processed with a photoresist), conditions for goodelectroplating results with vigorous electrolyte agitation are listed inTable II below:

TABLE II pH Co (M) mA/cm² CE (%) μm/seconds 2.0 0.006 22 50-56 210-230

A higher pH gives a larger current efficiency (“CE”), but lowering thepH allows a larger current density (“mA/cm²”) and electroplating rate(“m/seconds”). For patterned substrates, increasing the current density(“CD”) by about 10% over the current density for un-patterned substratesmay be necessary to optimize current density, current efficiency, etc.,in a manufacturing environment. During an electroplating operation, thepH of the electrolyte will rise. To lower the electrolyte pH, 12%perchloric acid is added, preferably using a metering pump.

An iron-cobalt-phosphorous alloy is stained in water. Rinsing the alloywithout damage can be performed by saturating the rinse water withcarbon dioxide (e.g., bubbling carbon dioxide through the rinse waterfor five minutes). Drying the alloy quickly with nitrogen blow-off willthen prevent the formation of brown stains on the alloy surface.

Sometimes, however, hand drying of the substrate can still allow someoxidation to occur. An alternative procedure for eliminating anystaining of the alloy during drying is to electroplate a thin (e.g., 300Å) layer of nickel on the iron-cobalt-phosphorous alloy. For example,after rinsing the substrate in water saturated with carbon dioxide, thecathode assembly is placed, still wet, into a sulfamate solutioncontaining 1 M of Ni(SO₃NH₂)₂, 0.03 M of NiCl₃, 0.6 M of H₃BO₃ at pH=4and a nickel anode. Electroplating at a current density of 2 mA/cm² forabout one minute produces a nickel layer thick enough (approximately 250Å) to protect the ferrous alloy from oxidizing in water.

Preferably, the addition of a buffer (e.g., up to about 0.1 molar) tothe electrolyte can help to maintain the surface pH low if agitationfrom the electroplating tool is insufficient to produce a bright andshiny deposit, which is a necessary but not sufficient condition for agood deposit. A non-complexing organic acid can be used if it hassufficient solubility and the proper acidity constant, K_(a). At firstorder, an effective buffer should have its logarithm acidity constantpK_(a) close to the target pH. The situation is complicated by the factthat the electrolyte is highly concentrated with salts (i.e., it hashigh ionic strength). The logarithm acidity constant pK_(a) of an acidis a function of ionic strength according to the Debye-Hückel equation:ΔpK _(a) =pK _(a) ′−pK _(a)=(2za−1)[(A(I)^(1/2))/(1+(I)^(1/2))−0.1I],wherein za is the charge on the conjugate acid species, A is a constant(A=0.51 for 20-30° C.), I is the ionic strength, and pK_(a)′ is theactual logarithm acidity constant pK_(a) in the ionic medium. Two casesof interest are summarized in Table III below, where “AP” is ammoniumphosphate, and “SHP” is sodium hypophosphite.

TABLE III CASE FE AP SHP CO I ΔpK_(a) 1 0.65 0.50 0.015 0.015 0.39−0.137 2 1.00 0.50 0.015 0.015 2.03 −0.097

Two acids that have good solubility and are not strong complexing agentsfor iron and cobalt are malonic acid (CH₂(COOH)₂, pK_(a)=2.83) andsarcosine (CH₃NHCH₂COOH, pK_(a)=2.21). Since the cathode consumeshydrogen H+, the highest buffering action occurs when the pH is belowthe pK_(a)′, so malonic acid should be a good buffer with an electrolyteat pH=2.5, and sarcosine should be a good buffer with an electrolyte atpH=2.0.

A phosphorous donor such as sodium hypophosphite in a 90 L electrolyteis preferably replenished on a maintenance basis using a metering pumpafter 1.3 grams thereof have been consumed (e.g., after electroplatingabout 3-4 eight-inch substrates, each electroplated 3.5 μm thick).Sodium hypophosphite is preferably added using an estimated consumptionbased on the percentage of phosphorus in the electroplated deposit suchas demonstrated in a substrate electroplating log. It should beunderstood that other donors such as boron may be included in theelectrolyte.

Thus, an electrolyte has been introduced including water, ascorbic acid,a donor such as a phosphorous donor (e.g., sodium hypophosphite),ammonium perchlorate, ferrous perchlorate, cobalt perchlorate, and abuffering agent of malonic acid, sarcosine, methanesulfonylacetic acid,phenylsulfonylacetic acid, and/or phenylmalonic acid. In an advantageousembodiment employable with an electroplating tool, a pH meter isimmersed in the electrolyte to monitor its pH and the electrolyte isfiltered with a microporous filter (e.g., 0.2-μm filter or better). Inan advantageous embodiment employable with an electroplating tool, theelectrolyte is substantially sealed to the atmosphere with a cover, anda substantially inert atmosphere is maintained above the electrolyte. Aninert gas (e.g., nitrogen) is bubbled through the electrolyte to removeoxygen.

Ammonium bicarbonate solution advantageously is added to the electrolyteduring an electroplating operation and during solution preparation toraise a pH thereof to approximately two. In a further advantageousembodiment, ammonium bicarbonate solution is added to the electrolyteduring an electrolyte preparation or an electroplating operation toraise a pH thereof in the range of about two to three. In anadvantageous embodiment, the ammonium bicarbonate solution has aconcentration of 150 grams per liter, and is added drop wise withagitation to the electrolyte. In one embodiment, phosphorus in theelectrolyte is replenished during an electroplating operation by addingelectrolyte containing a phosphorous salt. In an advantageousembodiment, the phosphorous salt is sodium hypophosphite.

In a further embodiment employable with an electroplating tool, aniron-cobalt anode is held in the electrolyte, wherein the iron-cobaltanode is substantially four atomic percent cobalt and 96 atomic percentiron. In a further advantageous embodiment, the iron-cobalt anodeincludes sulfur, vanadium, tungsten, copper, and/or combinationsthereof, with a concentration in the range of 1 to 100 ppm. In a furtherembodiment employable with an electroplating tool, a substrate is heldin the electrolyte, and the substrate is advantageously mounted in amagnetic field. In a further advantageous embodiment, the magnetic fieldis a rotating magnetic field. In a further advantageous embodiment, themagnetic field is produced with a current-carrying coil.

Conductive films such as copper films, particularly copper films formedon a silicon substrate by an electrodeposition process (e.g., the firstconductive winding layer 423 illustrated and described with reference toFIG. 9 above), generally develop mechanical stress after exposure tohigh downstream process temperatures. High downstream temperatures areencountered in processing steps such as sputtering and curing of aphotoresist. Development of film stress in copper is a consequence ofcopper having a higher coefficient of thermal expansion than silicon.Elevated temperatures thus lead to preferential expansion of the copperfilm and the development of a compressive stress therein at an elevatedtemperature by the less expansive silicon. Copper films approach thecopper yield stress in compression at 250° C., and again in tension whenreturned to room temperature. Copper films show significant stressdevelopment even after exposure to temperatures as low as 110° C. Theeffect of such stress is to induce a bow in the substrate on which it isdeposited when the substrate is cooled to room temperature. For example,the substrate 401 illustrated in FIG. 9 can develop a bow due tomismatch of the coefficients of thermal expansion of the substrate 401and the first conductive winding layer 423.

The substrate or wafer bow is the amount of deflection at the edgesthereof from a plane tangent to the center of the substrate. The radiusof curvature and substrate bow depend on thickness of the copper filmrelative to the thickness of the silicon substrate. To prepare such asubstrate with an electrodeposited copper film for further processingsteps, it is important to reduce the substrate bow, particularly the bowof a patterned substrate. Unrelieved copper stress can lead to laterincreased room-temperature film stress by inducing grain growth or bycausing sufficient mismatched thermal expansion stress to plasticallydeform the film.

A substantial portion of the residual copper film stress can be relievedin an advantageous embodiment by reducing the substrate temperature to astress-compensating temperature (e.g., well below room temperature).Even modest below-room temperature excursions lead to plastic filmdeformation, making the film more compressive and closer to astress-free level when the substrate temperature returns to roomtemperature or to an expected operating temperature. In effect, thereverse phenomenon is utilized to relax the residual mechanical stresspresent at room temperature in a copper film.

In an advantageous embodiment, a substrate after electrodeposition of acopper film is gradually cooled to well below room temperature (e.g.,−75 degrees Celsius) by placing the substrate in a suitablerefrigeration device at room temperature and turning on the devicecooling mechanism such as the device compressor. In an advantageousembodiment, the substrate is maintained at a temperature of −75 degreesCelsius for a period of 24 hours to obtain substantial stress relief. Ina further advantageous embodiment, the substrate is maintained at atemperature of −75 degrees Celsius for a period of six hours to obtainsubstantial stress relief. In a further advantageous embodiment, otherlow annealing temperatures to provide stress relief are contemplated.For example, a substrate can be placed inside a closed flat-pack in anoperating refrigeration device to slow the substrate cooling rate. In afurther advantageous embodiment, a substrate cassette containing aplurality of substrates can be placed inside an operating refrigerationdevice to slow the wafer cooling rate. After annealing at −75 degreesCelsius, the temperature of the substrate is gradually returned to roomtemperature. For example, the substrate can be gradually returned toroom temperature over a period of one hour.

When taken from a freezer at −75 degrees Celsius and warmed to roomtemperature, a substrate may become wet with condensation. Ifcondensation forms on the substrate surface, the substrate is preferablyplaced in front of a fan to fully bring its temperature to roomtemperature, and is then dried with a nitrogen gun.

Detailed procedures for ramping substrate temperatures to roomtemperature in a production environment would depend on the availableequipment. For instance, a freezer with programmable heating and coolingprofiles may be used, thereby avoiding or reducing condensation on thesurface of a substrate. Alternatively, the refrigeration and heatingprocess can take place in a vacuum device to reduce or even preventcondensation. By performing an annealing process, a substantial portionof the residual stress in a copper film deposited on a silicon substratecan be relieved, often reducing wafer bow by 90% or more.

Thus, a method of processing a substrate with a conductive film isintroduced to reduce mechanical stress therein after exposure to highdownstream process temperatures. In an advantageous embodiment, thesubstrate is a silicon, glass, or ceramic substrate. In an advantageousembodiment, the conductive film is formed on the silicon substrate by anelectroplating process.

The method includes reducing the temperature of the substrate to astress-compensating temperature well below room temperature andmaintaining the temperature of the substrate at the stress-compensatingtemperature for a period of time. In an advantageous embodiment, theperiod of time is one to 24 hours. The method further includesincreasing the temperature of the substrate to room temperature. In anadvantageous embodiment, reducing the temperature of the substrateincludes gradually reducing the temperature of the substrate at rate ofapproximately one degrees Celsius per minute. In an advantageousembodiment, the stress-compensating temperature is a temperature of lessthan zero degrees Celsius. In a further advantageous embodiment,increasing the temperature of the substrate to room temperature isperformed over a period of one to two hours.

In a further advantageous embodiment, the substrate is dried with inertgas within an inert gas environment after the increasing the temperatureof the substrate to room temperature. In an advantageous embodiment, theinert gas is nitrogen, and the inert gas environment advantageously is anitrogen environment.

In a related embodiment, a method of forming a micromagnetic device isintroduced herein that includes forming an insulating layer over asubstrate, forming a conductive winding layer over the insulating layer,forming another insulating layer over the conductive winding layer, andforming a magnetic core layer over the another insulating layer. Themethod also includes reducing a temperature of the micromagnetic deviceto a stress-compensating temperature, maintaining the temperature of themicromagnetic device at the stress-compensating temperature for a periodof time, and increasing the temperature of the micromagnetic deviceabove the stress-compensating temperature.

Those skilled in the art should understand that the previously describedembodiments of the micromagnetic devices, related methods, powerconverter employing the same, electroplating tool and electrolyte, andmethod of processing a substrate and micromagnetic device are submittedfor illustrative purposes only and that other embodiments capable ofproducing the same are well within the broad scope of the invention.Additionally, exemplary embodiments of the invention have beenillustrated with reference to specific electronic components, reagents,and processes. Those skilled in the art are aware, however, that othercomponents reagents, and processes may be substituted (not necessarilywith elements of the same type) to create desired conditions oraccomplish desired results. For instance, multiple components may besubstituted for a single component and vice-versa.

The principles of the invention may be applied to a wide variety ofpower converter topologies. While the micromagnetic devices, relatedmethods, electroplating tool and electrolyte, and method of processing asubstrate and micromagnetic device have been described in theenvironment of a power converter, those skilled in the art shouldunderstand that the aforementioned and related principles of theinvention may be applied in other environments or applications such as apower amplifier or signal processor.

For a better understanding of power converters see “Modern DC-to-DCSwitchmode Power Converter Circuits,” by Rudolph P. Severns and GordonBloom, Van Nostrand Reinhold Company, New York, N.Y. (1985) and“Principles of Power Electronics,” by J. G. Kassakian, M. F. Schlechtand G. C. Verghese, Addison-Wesley (1991). The aforementioned referencesare incorporated herein by reference in their entirety.

Although the invention has been described in detail, those skilled inthe art should understand that they can make various changes,substitutions and alterations herein without departing from the spiritand scope of the invention in its broadest form.

1. A method of forming a device, comprising: providing a substrate;forming a magnetic core layer over said substrate; increasing atemperature of said device to a curing temperature; reducing saidtemperature of said device to a stress-compensating temperature belowroom temperature; maintaining said temperature of said device at saidstress-compensating temperature for a period of time; and increasingsaid temperature of said device above said stress-compensatingtemperature.
 2. The method as recited in claim 1 wherein saidstress-compensating temperature is less than about zero degrees Celsius.3. The method as recited in claim 1 wherein increasing said temperatureof said device above said stress-compensating temperature includesincreasing said temperature of said device to about room temperature. 4.The method as recited in claim 1 wherein said substrate is a silicon,glass, or ceramic substrate.
 5. The method as recited in claim 1 whereinsaid reducing said temperature of said device includes graduallyreducing said temperature of said device at rate of approximately onedegree Celsius per minute.
 6. The method as recited in claim 1 whereinsaid period of time is greater than about one hour and less than about24 hours.
 7. The method as recited in claim 1 wherein increasing saidtemperature of said device above said stress-compensating temperature isperformed over a period of time greater than about one hour and lessthan about two hours.
 8. The method as recited in claim 1 furthercomprising drying said device with an inert gas after increasing saidtemperature of said device above said stress-compensating temperature.9. The method as recited in claim 1 further comprising forming aninsulating layer and a conductive winding layer between said substrateand said magnetic core layer.
 10. The method as recited in claim 1further comprising forming an insulating layer and a conductive windinglayer over said magnetic core layer.
 11. A method of forming a device,comprising: providing a substrate; forming a conductive winding layerover said substrate; increasing a temperature of said device to a curingtemperature; reducing said temperature of said device to astress-compensating temperature below room temperature; maintaining saidtemperature of said device at said stress-compensating temperature for aperiod of time; and increasing said temperature of said device abovesaid stress-compensating temperature.
 12. The method as recited in claim11 wherein said stress-compensating temperature is less than about zerodegrees Celsius.
 13. The method as recited in claim 11 whereinincreasing said temperature of said device above saidstress-compensating temperature includes increasing said temperature ofsaid device to about room temperature.
 14. The method as recited inclaim 11 wherein said substrate is a silicon, glass, or ceramicsubstrate.
 15. The method as recited in claim 11 wherein said reducingsaid temperature of said device includes gradually reducing saidtemperature of said device at rate of approximately one degree Celsiusper minute.
 16. The method as recited in claim 11 wherein said period oftime is greater than about one hour and less than about 24 hours. 17.The method as recited in claim 11 wherein increasing said temperature ofsaid device above said stress-compensating temperature is performed overa period of time greater than about one hour and less than about twohours.
 18. The method as recited in claim 11 further comprising dryingsaid device with an inert gas after increasing said temperature of saiddevice above said stress-compensating temperature.
 19. The method asrecited in claim 11 wherein forming said conductive winding layerincludes electroplating said conductive winding layer over saidsubstrate.
 20. The method as recited in claim 11 further comprisingforming an insulating layer and a magnetic core layer over saidconductive winding layer.